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OPERATING INSTRUCTIONS

ZF synchromesh transmissions
16 S 151, 16 S 181
16 S 221, 16 S 251
1315 758 101e

Subject to alterations in design

Copyright by ZF
This document is protected by copyright. Any reproduction and dissemination in whatever form even in adapted,
paraphrased or extracted form in particular as a reprint, photomechanical or electronic reproduction or as storage in data
processing equipment or data networks without approval by
the holder of the copyright is prohibited and will be prosecuted
under civil and criminal law.
Printed in Germany
ZF Friedrichshafen AG, MKS-K / 1992
Edition: 10.2001

Preface

Your vehicle is equipped with a synchromesh transmission of the ZF-ECOSPLIT model range.
The more familiar you are with the Ecosplit transmission, the more economically you will be able to drive
with it. These operating instructions inform you of how
to make the best use of the technical advantages of the
ZF transmission. Therefore, please carefully read these
operating instructions and any special instructions
provided by the
vehicle manufacturer before driving the vehicle for the
first time.

To ensure safe and reliable operation, please comply


with all maintenance instructions. Skilled ZF AfterSales Service personnel are available to maintain your
transmission and to assist you with any problems.
We wish you safe and pleasant driving with your ZF
transmission
ZF Friedrichshafen AG
Commercial Vehicles/Special Transmissions
Division
D-88038 Friedrichshafen
Germany
Tel.:
+ 49 7541 77-0
Fax:
+ 49 7541 77-90 80 00
Internet:
www.zf.com

Important safety information


The following safety instructions are used in this
operating manual:

! DANGER
Non-observance of safety instructions may lead to
operational errors, damage to or destruction of the
unit. As a consequence, operators or other persons
may be injured or their life may be at risk.

NOTE
Refers to special processes, techniques, data, use of auxiliary
equipment, etc.

!
CAUTION
This is used when incorrect, unprofessional working practices may damage the product.

DANGER
This is used when lack of care may lead to
personal injury or death or damage to property.

THREATS TO THE ENVIRONMENT!


Lubricants and cleaning agents must not be allowed to
enter the soil, ground water or sewage system.
Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
Collect used oil in a suitably large container.
Dispose of used oil, dirty filters, lubricants
and cleaning agents in accordance with
environmental protection guidelines.
When working with lubricants and cleaning
agents, always refer to the manufacturers
instructions.

Contents

Page
1

Technical data ....................................................... 4

2
2.1
2.2
2.3
2.4
2.5

Description
Design .....................................................................
Configuration ..........................................................
Gearshift system ......................................................
Servoshift.................................................................
Auxiliary units .........................................................

5
5
7
9
9

3
3.1
3.2
3.3
3.3.1
3.3.2
3.3.3
3.4
3.4.1
3.4.2
3.5
3.6
3.7

Operation
Starting the engine and setting off...........................
Operating the clutch ................................................
Gear selection ..........................................................
Shift pattern .............................................................
Changing gear..........................................................
Changing gear with servoshift.................................
Engaging and disengaging PTOs.............................
Clutch-dependent PTOs...........................................
Engine-dependent PTOs ..........................................
Parking.....................................................................
Tow-starting.............................................................
Towing away ............................................................

10
10
11
11
13
15
16
16
17
17
17
18

Page
3.8
3.9

Emergency operation ............................................... 19


Starting the vehicle at
sub-zero temperatures.............................................. 20
3.9.1 Parking the vehicle at sub-zero temperatures .......... 20
4
4.1
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9

Maintenance
Transmission oil.......................................................
Oil grades.................................................................
Oil fill quantities......................................................
Oil change intervals .................................................
Oil change................................................................
Draining off old oil .................................................
Oil fill ......................................................................
Oil level check .........................................................
Maintenance of transmission (version
with heat exchanger)................................................
Checking clutch operation .......................................
Checking release valve at the clutch pedal .............
Transmission breather..............................................
Maintenance of the pneumatic system ....................
Type plate.................................................................

21
21
21
21
22
22
23
23
24
25
26
27
27
28

Technical data

Model

for standard drive

Input torque

max. Nm

Ratios

1)

16 S 151

16 S 181

16 S 221

16 S 251

1600 / 1850

1900 / 2200

2200 / 2500

2700

Forwards gears

16.41 - 1.00 / 13.80 - 0.84

13.80 - 0.84

Reverse gears

15.36 - 12.92 / 12.92 - 10.80

12.92 - 10.80

Speedometer

electronic

Installation2)

z=6
Horizontal, to the left with integrated clutch bell housing

Gearshift

4-speed section Forwards gears with synchromesh, reverse gear with constant mesh

Range change and splitter group With synchromesh


4-speed section Via horizontal turning shaft control 3) with double H shift pattern
or superimposed H shift pattern

Shift actuation

Range change group4) Double H: changeover conducted automatically with appropriate selection
Superimposed H: changeover using preselection switch on shift lever
Splitter group4) Preselector valve on shift lever
Weight (without auxiliaries) approx. kg

289

315

319

334

Oil vol. for standard install.

approx. l

11

13

13

13,5

approx. l

10

10

11

for oil change


Oil grade

In accordance with the current ZF List of Lubricants TE-ML 02


1)
2)
3)
4)
5)

5)

Approximate value (depends on vehicle type and vehicle data as well as relevant application).
Here, the ZF Guidelines for installing manual transmissions (1203 765 110) should also be noted.
Turning shaft control connection can be adapted to the installation conditions in the vehicle.
Air pressure required = 6.2 to max. 10 bar; pressure red. valve (ZF no. 0501 204 036) must be fitted for higher pressure levels.
Transmission inclination 0 to 3
1315 758 101e

Description

Description

2.1

Design

Fig. 2 Double H shift pattern

ZF-Ecosplit transmissions comprise a 4-speed section, a


range-change group and a splitter group.
2.2

Configuration
4-speed section:
synchromesh, reverse gear with constant mesh
manual shift control (turning shaft control)
double H shift pattern or superimposed H shift pattern
Servoshift
Range change group, rear-mounted:
synchromesh
automatic changeover (pneumatic) when shifting
between gates 3/4 and 5/6 or vice versa (Fig. 2)
with double H pattern
changeover using preselector switch on shift
lever with superimposed H pattern (Fig. 3a)

Selector pattern I

R
1-4
5-8
N

Splitter group, front-mounted:


synchromesh
pneumatic changeover by preselector valve on
shift lever for (Fig. 3 and 3a), then actuating
clutch.

Selector pattern II

Automatic changeover (double H)


Reverse gear
Low range-change group
High range-change group
Neutral

Selector pattern I

Selector pattern II

Fig. 2a Superimposed H shift pattern


1315 758 101e

Description

Fig. 3
Double-H *
shift lever

Fig. 3a
Superimposed H *
shift lever

high

Range-change
group
high

low
high
high

tter
Spli
p
grou
Range-change
group

Splitter group

low

low

low
3

N
N

7
3

5
1

6
4

6
2

* Please note vehicle manufacturer data

8
4

1315 758 101e

Description

2.3

Gearshift system
Range-change group, double H shift pattern

Range-change group, superimposed H shift pattern

The shift system is divided into 5 adjacent gates. There is


a spring-loaded neutral position in gates 3/4 and 5/6.
Unequal spring detent strengths mean that all
positions can be easily located in the shift pattern.
The pneumatic changeover of the range-change group is
performed automatically when shifting from gate 3/4 to
5/6 or vice versa.

The shift system is divided into 3 adjacent gates. There


is a spring-loaded neutral position in gates 3/4 and 7/8.
The pneumatic changeover of the range-change group
for gate 3/4 to 5/6 or vice versa is performed using a
preselector switch on the shift lever (Fig. 3a).

Fig. 4
ZF double H shift pattern

Fig. 4a
ZF superimposed H shift pattern

1315 758 101e

Description

The range-change group shift control system comprises


a shift valve (35) and a double-action pneumatic cylinder (34) fitted in the transmission.

35

Splitter group
The splitter group is operated by means of a toggle
switch fitted to the shift lever (Fig. 3 and 3a). The low or
high splitter group is preselected by the driver using this
switch and shifted when the clutch is depressed.
NOTE
Changeover is performed when the clutch is fully
depressed.

34

Any gear can be split depending on the application


conditions of the vehicle.
Please also refer to vehicle manufacturers instructions.

017853

Fig. 5
34 Pneumatic cylinder
35 Shift valve

1315 758 101e

Description

2.4 Servoshift

2.5

The Servoshift system consists of a mechanical-pneumatic control unit and a double-action


pneumatic cylinder.

Auxiliary units
Depending on the vehicle configuration, the Ecosplit
transmission may be equipped with the following
auxiliary units (Fig. 7):

Shifting Ecosplit transmissions with Servoshift is performed as described under 2.3 (Fig. 4 and 4a), but with
pneumatic support.
Advantages are: considerably shorter gear lever
travel,
reduced shift forces

Fig. 7

WSK

Fig. 6

+ NMV

Vehicledependent
PTO
N ... PL

Clutch-dependent
PTOs
N1, N4 and N10

011359

017083

1315 758 101e

Integrated
ZF-Intarder

Enginedependent
PTO
NMV 221

Operation

Operation

3.1

Follow the operating information provided below to


drive economically and save fuel:

15

25

5
0

Apply the parking brake (to prevent the vehicle


from accidentally starting to move).
Shift the transmission into neutral.
Start the engine.
Engage gear (preferably 1st gear to protect clutch)
Release parking brake and gently engage clutch. Also
note manufacturers instructions.

20

10

rpm x 100

30

Drive in the medium engine


speed range.
Drive in the highest possible
gear.

DANGER
When leaving the vehicle with the engine running,
activate parking brake. This prevents undesired vehicle
rolling.

3.2
React to traffic conditions
well in advance.
Avoid unnecessary braking
and accelerating.

10

Starting the engine and setting off

Operating the clutch


Always fully depress the clutch.

CAUTION
Changing gear when the clutch is not fully disengaged
causes additional wear to the synchronizers in the transmission.

1315 758 101e

Operation

3.3

Gear selection

The gate for reverse gear is safeguarded by a springloaded stop and requires a greater amount of force to
overcome.

ZF-Ecosplit transmissions are synchromesh transmissions.


Synchronizers ensure that the meshing gears for the
required gear are rotating at the correct speed and in the
correct direction before the gear is engaged. You can
therefore change gear quicker and more reliably:

Unequal spring detent strengths mean that all positions


can be easily located in the shift pattern, i.e. the gates
can be found easily.
7

without double-declutching when changing up,

GP changeover 5

without blipping the throttle and double-declutching


when changing down, even when driving downhill
and in difficult traffic situations.

N
6

4
2

3.3.1 Shift pattern

Double H
The double H shift pattern (Fig. 8) includes a springloaded neutral position (idling position) in gates 3/4 (low
range-change group) and 5/6 (high range-change group).
In order to select gears 1/2 or 7/8, move the selector lever
against the spring force in the required direction and hold
the lever against this force when making the engagement
stroke. The gear lever returns to the neutral position if
released in the central area. The slow range-change group
is separated with a stronger spring force (GP
changeover) than the high range-change group.

Toggle switch up:


High splitter group (H)
Toggle switch down:
Low splitter group (L)
010876/017855

Fig. 8 Shift lever with double H shift pattern and splitter lever

1315 758 101e

11

Operation

Superimposed H
The superimposed H shift pattern (Fig. 8a) has a springloaded neutral position (idling position) in gates 3/4
(low range-change) and 7/8 (high range-change).
In order to select gears 1/2 or 5/6, move the
selector lever against the spring force in the required
direction and hold the lever against this force when
making the engagement stroke. The gear lever returns to
the neutral position if released in the central area.

3
5
1

8
N

4
6
2

The reverse gate is fitted with a spring loaded stop


which must be overcome by deliberate effort.
Toggle switch up:
High splitter group (H)
Toggle switch down:
Low splitter group (L)(L)
010877/017857

Fig. 8a Shift lever with superimposed H shift patter and


splitter switch and range-change lever

12

1315 758 101e

Operation

3.3.2 Changing gear

002 694

CAUTION
To protect the transmission, always fully disengage the
clutch.
To avoid causing severe damage to the transmission and
engine, only change down a gear if the vehicle has been
braked to below the maximum speed for the intended
gear.
Move gear lever quickly but gently. This is particularly
important when the transmission oil is cold. It is best
to move the gear lever with the open palm of your
hand, as shown in Fig. 9.
When engaging a gear, hold the selector lever against
the pressure point until the synchronization process is
complete and the gear is engaged.
Double H
To move between gates 3/4 and 5/6, strike the gear
lever briefly with a palm of your hand, then moved
swiftly onwards into the desired gear (Fig. 9).

Fig. 9
Changing gates
when
upshifting
downshifting

002 701

NOTE
When the transmission is cold, gearshifting requires
increased shift effort. If the range-change group does
not change over when changing down from gate 5/6 into
gate 3/4, slow your vehicle and engage the appropriate
gear at a lower speed

CAUTION
Changing between gates 5/6 and 3/4 at a vehicle speed of
more than approx. 28 km/h is not permitted.
A gate change causes the rear-mounted range-change
group synchromesh to switch ranges and at vehicle speeds
of more than approx. 28 km/h, this will result in premature
wear.

1315 758 101e

13

Operation

Superimposed H
The range-change shift is pre-selected on the switch on
the shift lever. If, for example, drivers want to shift from
4th gear in the basic transmission into 5th gear, he must

7
3
5
1

high
8
4

N
6
2

Range-change group

preselect the high group on the switch


disengage the clutch

017856/010877

shift the transmission to neutral the rangechange group then begins to change over

low

Fig. 9a

select gate 1/2


shift the basic transmission into 1st gear the rangechange group has in the meantime changed over to
high

Reverse gear
CAUTION
Only engage reverse gear when the vehicle is at a standstill.

engage clutch
Reverse gear may only be selected or deselected
when the clutch is open.

leave preselection switch in selected group


NOTE
Only actuate preselection switch if the range-change
group is to be shifted directly afterwards.

14

The clutch should be disengaged at idling engine


speed.
Only select reverse gear once the countershaft
has come to a standstill. If the countershaft is not
at a standstill, grating will occur when selecting
reverse gear.

1315 758 101e

Operation

NOTE
Service life periods differ depending on the
operating mode and may be reduced by short initial
synchromesh speed-matching, preferably of 1st gear.

3.3.3 Changing gears with Servoshift

Selecting and deselecting reverse gear. Grating when


selecting reverse gear is not permissible.
If necessary, lengthen waiting time before engagement
or investigate separating characteristics of clutch (refer
to Section 4.5).

CAUTION
Permanent shifting at high manual shift forces may result
in increased wear of synchronizer parts.

Changing gears with Servoshift is performed as


described under Section 3.3.2.

Slowly engage clutch.

Only perform shifts when the clutch is fully separated.


NOTE
Should the Servoshift fail, shifting may be performed at
considerably raised manual shift force.

1315 758 101e

15

Operation

3.4

Engaging and disengaging PTOs

Selecting and deselecting PTO. Grating when


selecting the PTO is not permissible.
If necessary, lengthen waiting time before engagement
or investigate separating characteristics of clutch (refer
to Section 4.5).

3.4.1 Clutch-dependent PTOs


Operation when the vehicle is stationary or
moving

Slowly engage clutch.


Engaging / disengaging
CAUTION
Gear changes are not permitted during PTO operation.
If parking the vehicle for a long period of time (e.g.
overnight) always disengage the PTO.

PTO may only be engaged or disengaged when the


clutch is open.
Clutch disengagement should be conducted at idling
engine speed.

Gear blocking (option)


Only engage PTO once countershaft has come to
standstill. If the countershaft is not at a standstill,
grating will occur when engaging the PTO.

Gear blocking is required if


the PTO is engaged and the vehicle MUST not move

NOTE
Service life periods differ depending on the operating
mode and may be reduced by short initial synchromesh
speed-matching, preferably of 1st gear.

16

1315 758 101e

during travel, PTO engagement must be prevented.

Operation

3.4.2 Engine-dependent PTOs

3.5

Parking

This type of PTO is engaged regardless of the vehicle


clutch.

Shift transmission into low range-change group


(1st - 4th gear).

The PTO must always be engaged or disengaged when


the engine is running:
min. engine speed 600 rpm
max. engine speed 2000 rpm
Engine-dependent PTOs can be operated when the
vehicle is moving or stationary.

Apply the parking brake.


For extra safety, engage a gear:

NOTE
When engaging the PTO, the following engine speeds
must not be exceeded:
2000 rpm for PTO ratio of 0.98
1300 rpm for PTO ratio of 1.55
depending on the inertia and drag torque levels to be
engaged.

Loaded vehicles should also be secured by placing


chocks under the wheels.

NOTE
Refer to operating manual 1315 758 150.

3.6

Vehicle facing uphill:

a forwards gear

Vehicle facing downhill:

reverse gear

Tow-starting
Start the engine by towing with a gear engaged in the
high range-change group.

CAUTION
To prevent damage inside the transmission, only tow-start
the vehicle in the high range-change group (gears 5-8).
Furthermore, the vehicle must not be tow-started in
reverse gear.

1315 758 101e

17

Operation

3.7

Towing away
[i axle]

Vehicles can only be towed away under the


following conditions:

8.0

vehicle fitted with emergency steering pump


high range-change group selected, shift lever in
neutral position
max. towing distance 100 km
the max. permissible towing speed has to be determined using the diagram shown (Fig. 10) and
depending on the axle ratio and tyre size.

Rdyn 0.5[m](e.g.275/80R22.5)

7.0

Rdyn 0.6[m](e.g.F24)

6.0

Rdyn 0.4[m](e.g.245/70R19.5)

5.0
4.0
3.0

NOTE
Always observe instructions provided by the
vehicle manufacturer.

2.0
10

15

20

25

30

35

40

45

50

V [km/h]

CAUTION
If any of the above conditions are not fulfilled, the propshaft must be disconnected at the rear axle the stub shafts
must be removed.
If there is reason to suspect that the transmission unit is
damaged, disconnect the propeller shaft at the rear shaft
or remove the stub shafts.

18

Fig. 10
Example: iaxle= 6. Rdyn = 0.5 m
Towing speed according to diagram Vmax = 25 km/h

1315 758 101e

NOTE
Observe the relevant national legislation relating to
max. towing speeds.

Operation

3.8

Emergency operation

35

If a fault occurs when changing the range-change group


(e.g. when shifting up or down between gates 3/4 and
5/6), this may be due to one of the following reasons:

34

damage to pipework in pneumatic system.


shift valve (35) or shift cylinder (34) serving rangechange group is defective (condensate or contamination).
017083

NOTE
Vehicle can then only be driven if the low rangechange group (1st 4th gear) is engaged.
If the high range-change group is engaged when the
fault occurs, the vehicle must be towed away.

Fig. 11
34 Shift cylinder for range-change group
35 Shift valve for range-change group

1315 758 101e

19

Operation

3.9

Starting the vehicle at sub-zero temperatures

3.9.1 Parking the vehicle at sub-zero temperatures

The transmission is filled with oil in accordance with


ZF List of Lubricants TE-ML 02. At outside temperatures of less than 15 C, the suitability of the oil should
be checked in accordance with the List of Lubricants
TE-ML 02. If necessary, change the oil in the transmission.
Alternatively, before starting the engine, heat up the oil.
This can be done, e.g. using warm air which must not
exceed 130 C on the transmission itself.

DANGER
When leaving vehicle with engine running, activate
parking brake. This prevents undesired vehicle
rolling.
NOTE
For engine starting and driving away, refer to
Section 3.1
The vehicle manufacturer specifications MUST
be observed.

20

1315 758 101e

When parking the vehicle at outdoor temperatures


below 0 C, ensure that the low range-change group is
engaged in the transmission (shift lever in 1st gear
position or neutral position in gate 3/4).

Maintenance

Maintenance

Oil quantity/ Transm.

Regular maintenance improves the operating safety and


reliability of the transmission. It is therefore particularly
important that compliance is maintained with the correct maintenance intervals.

First fill

11

13

13.5

Oil changes

10

11

16 S 151 16 S 181/221 16 S 251

Oil fill quantity for normal installation (0 3 inclination)


4.1

Transmission oil

4.1.1 Oil grades

4.1.3 Oil change interval

NOTE
Only oils contained in the valid ZF List of Lubricants
TE-ML 02 are authorized for use in the transmission.
The List of Lubricants can be obtained from all the ZF
After-Sales Service Centres or on the Internet under
www.zf.com.

For oil change intervals, refer to ZF List of


Lubricants TE-ML 02.
NOTE
The oil change intervals indicated must be complied
with as the operating safety and reliability of the
transmission may otherwise be impaired.

4.1.2 Oil fill quantities


Fill the transmission with oil correctly in order to ensure
the precise oil quantity in the transmission (refer to
Section 4.2.2). The oil quantity is shown on the type
plate (fitted to side of transmission) and in the technical
data (Page 4).
Refer to Section 4.3 for instructions on checking the oil
level.
1315 758 101e

21

Maintenance

4.2

Oil change

CAUTION
Oil must not be allowed to drain into the ground, into the
water table or into the sewage system. Any excess oil must
be collected in an appropriate
container and properly disposed of in accordance with
environment regulations.

4.2.1 Draining off old oil

NOTE
Always change the oil after a long journey so that the
transmission oil is still warm and thin.

017850

Fig. 12
View from below,
1 Oil drain plug (60 Nm)
2 Oil drain plug with magnetic plugs (60 Nm)

22

DANGER
Contact with the transmission or the transmission oil may lead to skin burns.
Unscrew oil drain plugs from transmission
(Fig. 12, items 1 and 2) and collect used oil in suitable
container.
Tighten the oil drain plugs (1) to the indicated torque.
Clean oil drain plug and magnetic plugs (2), replace
seal ring and tighten to the indicated torque.

1315 758 101e

Maintenance

4.2.2 Oil fill

4.3

Pour in the oil through the oil filler hole (Fig. 13).

The oil level is correct when the oil reaches the lower
edge of the filler hole or when oil is already escaping
out of the oil filler hole.

Oil level check


DANGER
Insufficient oil in the transmission causes
damage. Risk of accident.
Check the transmission oil level at regular
intervals:
Check oil level with vehicle standing on level ground.
Do not check oil level immediately after a journey (or
incorrect results will be obtained). Only check the oil
level after the oil in the transmission has cooled down
(<40 C).
Unscrew oil filler plug (Section 4.2.2).

017083

Fig. 13
Position of oil filler hole and overflow measurement

If the oil level has fallen below the edge of the oil
filler hole, more oil must be added (Section 4.2.2).
NOTE
Every time you check the oil, also check the
transmission for any oil leaks.

1315 758 101e

23

Maintenance

4.4

Transmission maintenance (version with heat


exchanger)

Check:
- Allow engine to run at idling speed for approx.
3 minutes.
- Shift transmission into neutral.
- Switch off engine.
- Conduct oil level check has described under 4.3.

NOTE
Maintenance work relevant for the standard transmission version should be carried out.
The following points should also be noted:
Oil draining:
- Unscrew oil drain screw from heat exchanger.
Oil filling:
- After the oil overflow test (Section 4.2.2), screw in
the oil fill hole screw.
Tightening torque = 60 Nm.
- Shift transmission into neutral.
- Allow engine to run at approx. 1200 rpm for around
2 - 3 minutes. This is required to ensure that the heat
exchanger and connection pipes are filled completely
with oil.
- Switch off engine.
- Again top up with oil until it overflows.

24

Fig. 14
Diagram: Ecosplit transmission with heat exchanger

1315 758 101e

000 508

Maintenance

4.5

Checking clutch operation


To guarantee the service life and trouble-free operation
of the synchromesh system, it is absolutely essential
that the clutch disengages without any difficulties. This
is also important for operation of clutch-dependent
PTOs.
Perfect clutch disengagement can be checked as
follows:
Allow the engine to run at idling speed and depress
clutch;
After max. 20 sec. *, slowly engage reverse gear.
In the event of any grating noise from the
selector teeth (scraping noise from the shift dogs)
during this check, the clutch MUST be reset and/or
checked.

* Depending on mass of the flywheel and temperature

1315 758 101e

25

Maintenance

4.6

Checking the release valve at the clutch pedal

The clutch must be fully disengaged before the splitter


group is shifted by the release valve (37).

CAUTION
The lock synchronizer may be irreparably damaged if the
splitter group is engaged and the release valve is incorrectly
set.

17

37

To check

min. 1mm clearance


000 340

The clutch must be set according to the vehicle


manufacturers instructions.

21

Fig. 15

The adjusting screw on the clutch pedal must be set


so that the release valve (37) is only activated in the
overtravel range (c).
The clutch is fully disengaged when in position (b) (to
check this, see Section 4.5). There must be clearance
of at least 1 mm between the release valve (37) and
pedal stop screw in this position.

26

a
b
c
d
17
19
21
32
37

1315 758 101e

Clutch engaged position


Clutch fully disengaged position
Overtravel range of clutch
End stop
Master cylinder for hydraulic clutch operation
From compressed air tanker
To clutch slave cylinder
To relay valve for splitter group
Release valve for splitter group

19
32

Maintenance

4.7

Transmission breather

4.8

The transmission oil heats up during travel. This


causes overpressure in the transmission which must be
continually vented through a breather valve.
Check that this valve is always operating correctly. The
breather (Fig. 16) must be kept clean. Do not cover with
a cap.

Maintenance of the pneumatic system


All pneumatic systems suffer from a buildup of condensate. Service the pneumatic system at regular intervals
to prevent condensate, rust and other impurities from the
compressed air tanks from entering the valves or shift
cylinders. The compressed air tanks must be drained
weekly. This should be done daily in winter.
NOTE
Drain the compressed air scrubber and water separator
when draining the compressed air tanks, unless these are
automatic units.
For this operation, observe the vehicle manufacturers
instructions.

017083

Fig. 16
Transmission breather valve

1315 758 101e

27

Maintenance

4.9

Type plate
The type plate contains the most important transmission
data. It is located on the left side of the transmission (in
direction of drive).
Please always quote the following information in the
event of queries or repairs:
1. Transmission parts list no.
2. Transmission type
3. Transmission serial no.

ECOSPLIT

16 S 181

1316 055 106

011356

XXXXXXX
16.41 - 1.0
13
Fig. 17
Sample type plate

28

IMP/U6.00
02
005001

1315 758 101e

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